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WO2001002150A1 - Procede de moulage par insertion permettant de former un element de grille de polarisation - Google Patents

Procede de moulage par insertion permettant de former un element de grille de polarisation Download PDF

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Publication number
WO2001002150A1
WO2001002150A1 PCT/US2000/017723 US0017723W WO0102150A1 WO 2001002150 A1 WO2001002150 A1 WO 2001002150A1 US 0017723 W US0017723 W US 0017723W WO 0102150 A1 WO0102150 A1 WO 0102150A1
Authority
WO
WIPO (PCT)
Prior art keywords
film
transreflector
dome
conductive
forming
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
PCT/US2000/017723
Other languages
English (en)
Other versions
WO2001002150A9 (fr
Inventor
Ronald A. Vandendolder
George D. Winslow
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Telaxis Communications Corp
Original Assignee
Telaxis Communications Corp
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Telaxis Communications Corp filed Critical Telaxis Communications Corp
Priority to AU11865/01A priority Critical patent/AU1186501A/en
Publication of WO2001002150A1 publication Critical patent/WO2001002150A1/fr
Anticipated expiration legal-status Critical
Publication of WO2001002150A9 publication Critical patent/WO2001002150A9/fr
Ceased legal-status Critical Current

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
    • B29C45/14778—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles the article consisting of a material with particular properties, e.g. porous, brittle
    • B29C45/14811—Multilayered articles
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01Q—ANTENNAS, i.e. RADIO AERIALS
    • H01Q15/00—Devices for reflection, refraction, diffraction or polarisation of waves radiated from an antenna, e.g. quasi-optical devices
    • H01Q15/14—Reflecting surfaces; Equivalent structures
    • H01Q15/141—Apparatus or processes specially adapted for manufacturing reflecting surfaces
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
    • B29C45/1418—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles the inserts being deformed or preformed, e.g. by the injection pressure
    • B29C2045/14237—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles the inserts being deformed or preformed, e.g. by the injection pressure the inserts being deformed or preformed outside the mould or mould cavity
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2995/00—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds
    • B29K2995/0003—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds having particular electrical or magnetic properties, e.g. piezoelectric
    • B29K2995/0005—Conductive
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49002—Electrical device making
    • Y10T29/49016—Antenna or wave energy "plumbing" making

Definitions

  • New applications continue to be developed for radio signaling in the microwave and higher frequency ranges.
  • certain scanning radar systems operating in the range of 77 GigaHertz (GHz) can provide collision warning and avoidance information for controlling motor vehicle traffic.
  • moving and stationary obstacles in front of the vehicle are detected by the radar system.
  • Post-processing modules analyze the radar data and, when necessary, the driver is alerted.
  • critical situations when driver reaction is too slow
  • such systems can also be used to automatically apply the brakes.
  • Other developed technologies in this area relate to adaptive cruise control of vehicle systems, which adapt the speed and distance of a vehicle to a preceding vehicle.
  • MMIC Monolithic Microwave Integrated Circuit
  • LMDS Local Multipoint Distribution Service
  • a hub transceiver services several different subscriber locations located within a given area, or cell, approximately up to six miles in diameter.
  • the implementers of vehicle radar, data transmission, and other microwave radio systems continue to be faced with several challenges at the present time.
  • One challenge is in the electronics technology needed to implement these systems.
  • Transceiver components must provide precise control over signal levels in order to effect the maximum possible link margin at the receiver.
  • these systems must typically use a highly directional (i.e., narrowly focused) antenna that has very low cross polarization levels.
  • the transceiver equipment, including the antenna also typically needs to be small, compact, and light weight.
  • antennas for both LMDS service and microwave radars that use a so-called folding optics design.
  • Such a design uses a device known as a transreflector placed in a plane orthogonal to the intended axis of the antenna and a twist reflector assembly also placed in the same plane.
  • This type of antenna typically requires fabrication of multiple individual components. See, for example, the antennas described in U.S. Patent No. 5,455,589 issued to Huguenin, G.R. and Moore, E.L. on October 3, 1995 and assigned to Millitech Corporation, the assignee of the present application, as well as U.S. Patent No. 5,680,139 issued on October 21, 1997 to the same inventors, also assigned to Millitech Corporation.
  • the transreflectors used in these designs are fabricated as a structure with a curved surface on which a grid of fine parallel wires is disposed at closely spaced intervals.
  • the interval spacing depends upon the frequency of the radio energy expected to be transmitted or received by the antenna.
  • the grid serves as a polarizer for electromagnetic radiation, and the convex surface functions as a focusing reflector for the component of radiation having a polarization parallel to the wires.
  • the present invention is a process for manufacturing a compact, light weight, inexpensive transreflector element for use in an antenna.
  • the antenna consists of an exterior shaped housing, or dome, formed of an inexpensive resilient material such as plastic.
  • a polarizing metal grid is formed along an interior surface of the dome or within the internal surface of the dome.
  • the process begins with a thin flat sheet of a suitable film substrate.
  • the film may, for example, be LexanTM or another polycarbonate.
  • a conductive grid defining the electromagnetic properties of the transreflector is then laid down on the film such as by screening a conductive an ink grid.
  • the sheet is then formed to the desired dome shape such as by vacuum forming it over a suitably shaped mold while applying heat. The formed shape is then trimmed to size.
  • the formed part is then inserted into an injection mold die.
  • the injection mold defines the ultimately desired external shape for the transreflector dome.
  • Thermoplastic resin or other suitable material for forming the dome is then injected directly against the film while it is in the die. As a result, the film becomes an integral part of the molded transreflector assembly.
  • the screened film consists of the wire grid layers screen printed on the outer surface of the film, with a protective hard coat layer formed over the printed wires.
  • the hard coat layer gives wear and chemical protection to the grid lines.
  • Other techniques may involve multiple film layers with a top layer screened on either a first or second surface and a second layer then being bonded to the first using a heat activated adhesive.
  • the second film layer can be used to protect the surface having the wire grid molded thereon from the later melt process during the injection molding resin step.
  • the present process has several advantages over other techniques.
  • One significant advantage of this method is the ability to incorporate the metallic grid as a part of the complex dome shape without additional processes.
  • the metallic grid is screen printed using inks, and a number of known processes can be used to obtain the desired high accuracy.
  • This process also permits the transreflector to be formed as an integral part together with any supporting structure or alignment features as well. Finally, the process results in a low cost transreflector with minimal component part counts.
  • Fig. 1 is an exploded isometric view of a microwave antenna assembly that includes a transreflector manufactured according to the invention.
  • Fig. 2 illustrates a polycarbonate sheet and grid lines screened thereon.
  • Fig. 3 illustrates a forming step.
  • Fig. 4 shows a formed insert part.
  • Fig. 5 shows the formed insert after it has been trimmed.
  • Fig. 6 illustrates the empty injection mold with the formed insert placed therein.
  • Fig. 7 shows the closed mold with thermoplastic resin flowing around the formed insert.
  • Fig. 8 shows the completed transreflector dome.
  • Fig. 1 is an isometric view of an antenna assembly 10 of which certain portions are manufactured according to the present invention.
  • the antenna assembly 10 consists of a main body or housing 12 formed of an appropriate suitable material such as an ABS thermoplastic.
  • the housing 12 has an outer portion thereof shaped as a thin plastic dome 14.
  • the dome 14 has an approximately parabolic shape in the preferred embodiment.
  • An alternative shape for the dome 14 is spherical.
  • the dome 14 has formed therein, on preferably an interior surface thereof, a parallel wire grid 15.
  • the thickness of the dome 14 is approximately one-half of the wave length of the frequency of operation within the dielectric material of the dome 14.
  • the second component of the antenna assembly 10 is a twist reflector or plate 20.
  • the twist plate 20 imparts a 90° rotation to electromagnetic energy in the polarization of the incident and reflected signals.
  • the twist plate 20 may be designed in many different ways; in the illustrated embodiment, the twist plate 20 has formed thereon a grooved conductive surface (not visible in Fig. 1) facing the interior of the housing 12.
  • a circular wave guide feed 23 is coupled to the center of the twist plate 20 and serves as a focal point for the received radiated energy and as a feed point for transmitted radiated energy.
  • the twist plate 20 typically also has mounted adjacent to the rear surface thereof a printed wiring board 30 on which are placed the components of a radio transceiver.
  • a rear cover 40 serves as both a conductive shield against interfering electromagnetic radiation and as a shield against the weather and other physical elements.
  • the dome 14 and more specifically the grid 15 define a central axis or line of sight axis for the antenna.
  • the specific arrangement of the grid lines 15 and the specific shape of the dome 14 are therefore critical as to orient this center axis properly.
  • Figs. 2 through 5 an initial series of steps used to manufacture the housing 12 incorporating the dome 14 and grid lines 15 will be described in detail.
  • a thin sheet or other carrier film 11 is coated with a pattern of conductive material as a series of parallel spaced lines in order to form the conductive grid 15.
  • the conductive lines may be formed with conductive ink through any number of decorative ink printing processes, or by vacuum depositors, etchings, and the like. In the case of etching, a metallic layer is first laid down upon the carrier film 11. Although a single sheet is shown in Fig. 2, it should be understood that at this point the carrier film 11 may also be formed from multiple sheets held together with adhesive coatings.
  • the preferred carrier film 11 is a thin polycarbonate sheet film such as LexanTM. However, other metalizable films may be utilized.
  • carrier film 11 as a base for defining and providing the structure for the grid 15, the conductive metal strips can be formed with a high degree of precision through a printing process using conductive ink containing metallic particles or by vapor deposition of a metal through a mask. Precision procedures for so doing are well known in the industry and readily adapted for forming the grid lines 15.
  • the carrier film 11 is then subjected to a vacuum forming process.
  • the carrier film 11 is placed adjacent to a mold 16 having the desired shape for the finished dome 12.
  • a heat source 17 is applied adjacent to the mold 16 and a vacuum is created to cause the film to warp to the desired shape.
  • a molded sheet such as shown in Fig. 4; the molded sheet is then trimmed to provide the ultimate desired shape of the dome 12 as shown in Fig. 5.
  • Figs. 6 through 8 illustrate the final steps in manufacturing the dome 12.
  • the formed carrier film 11 is then inserted into an injection mold containing two halves 19-1 and 19-2.
  • the injection mold halves 19-1 and 19-2 have corresponding curved surfaces 41-1 and 41-2 conforming to the ultimate desired shape of the dome 12.
  • the mold halves 19 are then clamped to one another as shown in Fig. 7 with the carrier film 11 placed there between.
  • a suitable molten thermoplastic resin or other suitable resilient material for forming dome 12 is then injected into the mold using an injection molding machine. The molten resin flows through the cavity in the mold 19 against the formed carrier film 11.
  • a retaining ring 45, a circular lip portion 46, mounting screw posts 47, and other supporting structures or alignment features may be defined by the injection mold and integrally formed with dome 12 if desired.
  • thermoplastic resins for forming the body of the dome 12 may include polycarbonates, polymethyl methacrylate, ABS, polyethylene, terephtlate and polybutylene terephtlate, and their alloys. In general, higher melt temperature engineering resins are not desirable for use in the present process.
  • the method of the present invention is effective in providing a high degree of precision in forming the fine lines which must be used to create the parallel wire grid 15.
  • the ink mold process allows transfer of the conductive lines using well known screen printing techniques.
  • the synthetic resin body of the transreflector is easily formed about the carrier film using known injection molding techniques and results in good bonding of the two materials as part of the molding process. As a result, transreflector antenna assemblies 10 may be produced at a relatively low cost with a high degree of accuracy.

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  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Mechanical Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Electromagnetism (AREA)
  • Injection Moulding Of Plastics Or The Like (AREA)
  • Aerials With Secondary Devices (AREA)

Abstract

La présente invention concerne un procédé pour fabriquer un boîtier bombé comprenant un élément transréflecteur destiné à être utilisé dans une antenne hyperfréquence. La partie bombée comprend une grille métallique de polarisation faisant partie d'une forme courbe complexe par utilisation d'un procédé de moulage par insertion. Ainsi, le composant transréflecteur peut être formé de façon économique en tant que partie intégrante de la structure de support et de tout élément d'alignement, sans recourir à des étapes de moulage supplémentaires ou à des parties de composant multiples.
PCT/US2000/017723 1999-07-01 2000-06-27 Procede de moulage par insertion permettant de former un element de grille de polarisation Ceased WO2001002150A1 (fr)

Priority Applications (1)

Application Number Priority Date Filing Date Title
AU11865/01A AU1186501A (en) 1999-07-01 2000-06-27 Insert mold process for forming polarizing grid element

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US09/346,425 1999-07-01
US09/346,425 US6246381B1 (en) 1999-07-01 1999-07-01 Insert mold process for forming polarizing grid element

Publications (2)

Publication Number Publication Date
WO2001002150A1 true WO2001002150A1 (fr) 2001-01-11
WO2001002150A9 WO2001002150A9 (fr) 2002-07-25

Family

ID=23359326

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/US2000/017723 Ceased WO2001002150A1 (fr) 1999-07-01 2000-06-27 Procede de moulage par insertion permettant de former un element de grille de polarisation

Country Status (3)

Country Link
US (1) US6246381B1 (fr)
AU (1) AU1186501A (fr)
WO (1) WO2001002150A1 (fr)

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2015173115A1 (fr) * 2014-05-16 2015-11-19 Robert Bosch Gmbh Support optique, procédé de réalisation d'un support optique, dispositif de réalisation d'un support optique et module radar

Families Citing this family (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US6563399B2 (en) * 2000-06-05 2003-05-13 Leo Love Adjustable azimuth and phase shift antenna
DE10038999A1 (de) * 2000-08-10 2002-03-21 Bosch Gmbh Robert Gehäuse für ein elektronisches Bauelement
JP2003215233A (ja) * 2002-01-24 2003-07-30 Murata Mfg Co Ltd レーダヘッドモジュール
US8745853B2 (en) * 2010-07-05 2014-06-10 Universal Display Corporation Antenna fabrication with three-dimensional contoured substrates

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WO1990004319A1 (fr) * 1988-10-05 1990-04-19 Rogers Corporation Corps en plastique incurve avec configuration de circuit et procede de production
US5162810A (en) * 1990-08-08 1992-11-10 Mikuni Plastics Parabolic antenna and process for manufacturing the same
EP0551526A1 (fr) * 1991-07-31 1993-07-21 Sumitomo Chemical Company Limited Procede pour mouler un article multicouche
US5830397A (en) * 1994-10-24 1998-11-03 Decoma International Inc. Method of making a vehicle window
US5876789A (en) * 1995-11-16 1999-03-02 Kabushiki Kaisha Toshiba Method and apparatus for manufacturing radio frequency board with curved surface
US6006419A (en) * 1998-09-01 1999-12-28 Millitech Corporation Synthetic resin transreflector and method of making same

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US4185287A (en) * 1977-07-25 1980-01-22 Texas Instruments Incorporated Mechanically scanned antenna system
DE3023562C2 (de) * 1980-06-24 1982-10-28 Siemens AG, 1000 Berlin und 8000 München Einrichtung zur Polarisationsumwandlung elektromagnetischer Wellen
US4482513A (en) * 1981-03-10 1984-11-13 General Dynamics, Pomona Division Method of molding foam/aluminum flake microwave lenses
US4632798A (en) 1983-07-27 1986-12-30 Celanese Corporation Encapsulation of electronic components with anisotropic thermoplastic polymers
US4937425A (en) * 1989-08-29 1990-06-26 Hughes Aircraft Company Method of making a polarizing parabolic dish antenna reflector
JPH06270175A (ja) 1991-05-15 1994-09-27 E I Du Pont De Nemours & Co 多段階圧縮成型により熱可塑性シート材料で封入したインサート
US5455589A (en) * 1994-01-07 1995-10-03 Millitech Corporation Compact microwave and millimeter wave radar
WO1998035403A1 (fr) * 1997-02-06 1998-08-13 Robert Bosch Gmbh Ensemble antenne hyperfrequence pour systeme radar de vehicule a moteur
US6014108A (en) * 1998-04-09 2000-01-11 Hughes Electronics Corporation Transverse-folded scanning antennas

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Publication number Priority date Publication date Assignee Title
WO1990004319A1 (fr) * 1988-10-05 1990-04-19 Rogers Corporation Corps en plastique incurve avec configuration de circuit et procede de production
US5162810A (en) * 1990-08-08 1992-11-10 Mikuni Plastics Parabolic antenna and process for manufacturing the same
EP0551526A1 (fr) * 1991-07-31 1993-07-21 Sumitomo Chemical Company Limited Procede pour mouler un article multicouche
US5830397A (en) * 1994-10-24 1998-11-03 Decoma International Inc. Method of making a vehicle window
US5876789A (en) * 1995-11-16 1999-03-02 Kabushiki Kaisha Toshiba Method and apparatus for manufacturing radio frequency board with curved surface
US6006419A (en) * 1998-09-01 1999-12-28 Millitech Corporation Synthetic resin transreflector and method of making same

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2015173115A1 (fr) * 2014-05-16 2015-11-19 Robert Bosch Gmbh Support optique, procédé de réalisation d'un support optique, dispositif de réalisation d'un support optique et module radar

Also Published As

Publication number Publication date
AU1186501A (en) 2001-01-22
WO2001002150A9 (fr) 2002-07-25
US6246381B1 (en) 2001-06-12

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